Honeywell International Inc.

Jimmy Wiggins

James Piascik

Eric Passman

Robert Franconi

William Lee Giesler

Martin Carlin Baker

Dean Robert Anderson

Leroy Allen Fizer

Brad King

Reza Oboodi

Richard Bryce Fox

Paul Chipko

Jacob Harding

Paul W Banta

Edward E Woodruff

Harry Lester Kington

Bahram Jadidian

Robbie Joseph Adams

Deepak Pitambar Mahajan

Robert Alan Dietrich

Glenn H Lane

Dori Marshall

Ronald J Louis

Mahdi Mohajeri

Narasimha Reddy Venkatarayappa

Peter Kenneth Zeiner

Yongbae Jung

Michael Kolic

William H Reed

Siva Bavisetti

Andre Robinson

Tom McHugh

Dave Oman

John L Doak

A method of making an electromagnetic coil for use in a high-temperature electromagnetic machine includes pre-coating magnet wire with a high-temperature insulation precursor to produce pre-coated magnet wire, winding, while applying in-situ a glass-ceramic slurry, the pre-coated magnet wire into a predetermined coil shape to produce a wet-wound green coil, and thermally processing the wet-wound green coil to produce a processed coil. In some instances, a second layer of a high-temperature insulation may be applied to the processed coil to produce a further insulated processed coil, and then thermally processing the further insulated processed coil to produce a further processed electromagnetic coil.

Method of assembling a high-temperature electromagnetic machine

Methods for fabricating wires insulated by low porosity glass coatings are provided, as are high temperature electromagnetic (EM) devices containing such wires. In embodiments, a method for fabricating a high temperature EM device includes applying a glass coating precursor material onto a wire. The glass coating precursor material contains a first plurality of glass particles having an initial softening point. After application onto the wire, the glass coating precursor material is heat treated under process conditions producing a crystallized intermediary glass coating having a modified softening point exceeding the initial softening point. The crystallized intermediary glass coating is then infiltrated with a filler glass precursor material containing a second plurality of glass particles. After infiltration, the filler glass precursor material is heat treated to consolidate the second plurality of glass particles into the crystallized intermediary glass coating and thereby yield a low porosity glass coating adhered to the wire.

Low porosity glass coatings formed on coiled wires, high temperature devices containing the same, and methods for the fabrication thereof

Embodiments of laminated stator cores suitable for usage in high temperature applications are provided, as are embodiments of methods for manufacturing high temperature laminated stator core. In one embodiment, the method includes obtaining a plurality of coated laminates each comprising a laminate over which a coating precursor layer is formed. The coating precursor layer contain inorganic dielectric particles having a softening point. The plurality of coated laminates are arranged in a laminate stack, which is then fired at temperatures equal to or greater than the softening point of the inorganic dielectric particles. During firing, a compressive force is applied to the laminate stack sufficient to consolidate the inorganic dielectric particles into a plurality of coherent interlaminate dielectric layers electrically insulating and bonding together the plurality of coated laminates as the high temperature laminated stator core.

High temperature laminated stator cores and methods for the manufacture thereof

A method for additively manufacturing an article includes providing or obtaining a build material, directing a first energy beam at the build material to raise the temperature of the build material above a melting point of the build material, and thereafter withdrawing the first energy beam to allow the build material to solidify into a first layer. The method further includes directing a second energy beam at the first layer, wherein the second energy beam differs from the first energy beam in that the second energy beam is of insufficient energy to cause melting of the first layer of build material and after directing the second energy beam at the first layer, providing additional build material over the first layer. The second energy beam will have an effect of reducing or eliminating residual stresses of each build layer. The energy of the second energy beam can be controlled using a thermal or optical feedback loop. Still further, the method includes directing a third energy beam at the additional build material to form a second layer that is metallurgically fused with the first layer. The process is repeated until an entire 3D shape of desired geometry is completed resulting in a part with reduced of free of residual stress or the potential of cracks within the 3D shape.

Methods for residual stress reduction in additive manufacturing processes

Methods for manufacturing high temperature laminated stator cores

An air turbine start system is provided that includes an air turbine starter, a starter air valve, a turbine speed sensor, and a circuit. The starter air valve is movable between an open position, in which the pressurized air may flow into the air turbine starter, and a closed position, in which pressurized air does not flow into the air turbine starter. The turbine speed sensor is coupled to the air turbine starter, and is configured to sense the rotational speed of the turbine and supply a rotational speed signal representative thereof. The circuit is coupled to receive the rotational speed signal and is configured, upon receipt thereof, to determine whether the starter air valve is in the closed position or an open position.

Air turbine start system with monopole starter air valve position

Embodiments of a gas turbine engine actuation system are provided, as are embodiments of a high temperature actuator and methods for the manufacture thereof. In one embodiment, the gas turbine engine actuation system includes an actuated gas turbine engine component and a high temperature actuator, which has a rotor mechanically linked to the actuated gas turbine engine component and a stator surrounding at least a portion of the rotor. The stator includes, in turn, a coil support structure having a plurality of spokes extending radially therefrom. A plurality of pre-formed electromagnetic coils is circumferentially distributed about the coil support structure. Each of the plurality of pre-formed electromagnetic coils is inserted over at least one of the plurality of spokes in a radial direction. The stator further includes an inorganic dielectric material in which each of the plurality of pre-formed electromagnetic coils is at least partially embedded.

Gas turbine engine actuation systems including high temperature actuators and methods for the manufacture thereof

A solenoid actuator includes a housing, a bobbin assembly, a coil, and a washer. The bobbin assembly is disposed at least partially within the housing, and includes a return pole and an armature. The return pole is fixedly coupled to the housing, and the armature is axially movable within the housing. The coil is disposed within the housing and is wound around at least a portion of the bobbin assembly. The washer is disposed between the coil and a portion of the bobbin assembly and surrounds a portion of the return pole. The washer is formed of an electrical insulator material.

High temperature solenoid actuator

Embodiments of an electromagnetic coil assembly are provided, as are methods for the manufacture of an electromagnetic coil assembly. In one embodiment, the method for manufacturing an electromagnetic coil assembly includes the steps of providing a braided aluminum lead wire having a first end portion and a second end portion, brazing the first end portion of the braided aluminum lead wire to a first electrically-conductive interconnect member, and winding a magnet wire into an electromagnetic coil. The second end portion of the braided aluminum lead wire is joined to the magnet wire after the step of brazing.

High temperature electromagnetic coil assemblies including brazed braided lead wires

By way of example, a method for manufacturing an electromagnetic coil assembly includes the steps of providing a braided aluminum lead wire having a first end portion and a second end portion, brazing the first end portion of the braided aluminum lead wire to a first electrically-conductive interconnect member, and winding a magnet wire into an electromagnetic coil. The second end portion of the braided aluminum lead wire is joined to the magnet wire after the step of brazing.

Method for manufacturing high temperature electromagnetic coil assemblies including brazed braided lead wires

A low leakage seal for separating two environments and contacting a component surface is provided. The seal includes a base and an annular rib. The annular rib is coupled to and extends from the base. The annular rib includes at least one contact surface configured to contact the component surface having a plurality of angularly cut radial grooves formed therein. The annular rib flexes and pressure energizes in the presence of a pressure differential between the two environments.

Over center high deflection pressure energizing low leakage seal

A starter air valve assembly includes a valve body, a flow control valve, a rate control servo mechanism, and a valve actuator. The valve body defines a flow passage having at least an inlet port and an outlet port. The valve is disposed at least partially within the flow passage and is moveable between an open position and a closed position. The rate control servo mechanism is adapted to receive pressurized fluid and is configured, upon receipt of the pressurized fluid, to supply a controlled flow of the pressurized fluid. The valve actuator is coupled to the valve and is in fluid communication with the rate control servo to thereby receive the controlled flow of the pressurized fluid. The valve actuator is configured, upon receipt of the controlled flow of the pressurized fluid, to move the valve between the closed position and the open position at a substantially controlled rate.

Pneumatic valve control using downstream pressure feedback and an air turbine starter incorporating the same

A starter air valve assembly includes a valve body, a flow control valve, a rate control servo mechanism, and a valve actuator. The valve body defines a flow passage having at least an inlet port and an outlet port. The valve is disposed at least partially within the flow passage and is moveable between an open position and a closed position. The rate control servo mechanism is adapted to receive pressurized fluid and is configured, upon receipt thereof, to supply a controlled flow of the pressurized fluid. The valve actuator is coupled to the valve and is in fluid communication with the rate control servo to thereby receive the controlled flow of the pressurized fluid. The valve actuator is configured, upon receipt of the controlled flow of the pressurized fluid, to move the valve between the closed position and the open position at a substantially controlled rate.

Pneumatic valve control having improved opening characteristics and an air turbine starter incorporating the same

Growing community of inventors

Chandler, AZ, United States of America

Jimmy Wiggins